Helmet liner assembly

ABSTRACT

A helmet having a helmet shell with an inner surface defining a cavity and a frontal opening is provided. The helmet includes a liner assembly for engagement with the helmet shell within the cavity, and which has a lateral liner portion including left and a right liner portions having an outer surface complementarily shaped relative to left and right inner surface portions of the inner surface, respectively. The left liner portion includes a left chin segment, and the right liner portion includes a right chin segment, with the chin segments being configured to engage one another proximate a front section of the helmet. The liner assembly also includes a central liner portion engageable between the left and right liner portions and having an outer surface complementarily shaped relative to a central portion of the inner surface portion for engagement therewith.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No.63/268,151, filed on Feb. 17, 2022, and entitled “HELMET LINERASSEMBLY”, which is incorporated by reference herein in its entirety.

TECHNICAL FIELD

The technical field generally relates to helmets, and more particularlyto helmets provided with a reinforced liner assembly.

BACKGROUND

Helmets used for outdoor activities typically include a shell thatdefines a cavity for housing a wearer's head, and a front opening toallow the wearer to see. The helmets also include a liner, or linerassembly, lining the inner surface of the shell to provide increasedcomfort and/or security to the wearer. Typical liner assemblies caninclude a foam piece in the general shape of the helmet shell. The foampiece can then be trimmed down to have the liner fit into the cavity.However, this process can leave gaps between the liner and the innersurface of the shell, thereby reducing the efficiency of the linerassembly.

Known liner assemblies can also be made of a plurality of piecesconfigured to engage one another within the cavity of the shell. Thesepieces of the liner assembly can be individually trimmed, or connectedto one another via adhesive or other components, then subsequentlytrimmed. This process can be generally more complex, which can causeincreased manufacturing time, along with increased labour costs.

There is therefore a need for a helmet provided with a liner assemblyadapted to overcome at least some of the drawbacks of what is known inthe field.

SUMMARY

According to an aspect, a helmet is provided. The helmet includes ahelmet shell having an inner surface defining a cavity and a frontalopening. The helmet also includes a liner assembly for engagement withthe helmet shell within the cavity, including a lateral liner portionincluding a left liner portion and a right liner portion, where each ofthe left and right liner portions has an outer surface complementarilyshaped relative to left and right inner surface portions of the innersurface, respectively, and configured to engage with same, where theleft liner portion includes a left chin segment, and the right linerportion includes a right chin segment. The left and right chin segmentsbeing configured to engage one another proximate a front section of thehelmet shell. The liner assembly also has a central liner portionengageable between the left and right liner portions and having an outersurface complementarily shaped relative to a central inner surfaceportion for engagement therewith.

According to a possible embodiment, the complementarily shaped outersurfaces of the left and right liner portions and the left and rightinner surface portions are adapted to engage one another to at leastpartially reduce relative movement between the left and right linerportions and the helmet shell.

According to a possible embodiment, the central liner portion includescentral engagement surfaces provided on either side thereof, and whereinthe left and right liner portions include respective lateral engagementsurfaces configured to engage with the central engagement surfaces.

According to a possible embodiment, central engagement surface includesone or more projections extending therefrom, and where each lateralengagement surface includes one or more recesses adapted to receiverespective projections therein, the projections and recesses beingadapted to cooperate to at least partially reduce relative movementbetween the central liner portion and the left and right liner portions.

According to a possible embodiment, the central engagement surfaces areshaped and sized to bias the left and right liner portions outwardly andaway from the central liner portion upon engagement of the central linerportion between the left and right liner portions.

According to a possible embodiment, the central liner portion includesrabbeted edges extending along left and right sides thereof.

According to a possible embodiment, the central engagement surfaces eachrabbeted edge includes at least one angled surface define a wedgeconfigured to bias the left and right liner portions outwardly and awayfrom the central liner portion upon engagement of the central linerportion between the left and right liner portions.

According to a possible embodiment, the rabbeted edges extend along anentire length of the left and right sides of the central liner portion.

According to a possible embodiment, the left and right liner portionseach include an overhang adapted to engage respective rabbeted edges anddefine rabbet joints therewith.

According to a possible embodiment, the rabbet joints extend along theentire length of the left and right sides of the central liner portion.

According to a possible embodiment, the helmet further includes a bottomopening, and wherein the central liner portion extends from a rearsection of the helmet shell proximate the bottom opening, along thecentral inner surface portion and to the front section proximate thefrontal opening.

According to a possible embodiment, the central liner portion includes afrontal segment adapted to be spaced from the inner surface of thehelmet shell, thereby defining a gap therebetween.

According to a possible embodiment, the left and right liner portionsinclude respective forward segments adapted to be spaced from the innersurface of the helmet shell, and wherein the gap is further definedbetween the inner surface of the helmet shell and the forward segments.

According to a possible embodiment, the front segment and the forwardsegments are adapted to define a continuous surface when the centralliner portion is coupled between the left and right liner portions.

According to a possible embodiment, the helmet further includes a chinguard provided at the front section of the helmet shell and at leastpartially defining a periphery of the frontal opening, and wherein theleft and right chin segments extend along the chin guard on respectivesides thereof and engage one another substantially at a middle point ofthe chin guard.

According to a possible embodiment, each one of the left and right chinsegments includes an engagement surface adapted to engage the engagementsurface of the other one of the left and right chin segments.

According to a possible embodiment, one of the engagement surfacesincludes a protrusion, and wherein another one of the engagementsurfaces includes a recess adapted to receive the protrusion thereinwhen the engagement surfaces engage one another.

According to a possible embodiment, the engagement surfaces aresubstantially flat or planar.

According to a possible embodiment, the engagement surfaces aresubstantially perpendicular relative to the chin guard proximate themiddle point.

According to a possible embodiment, each one of the left liner portion,the right liner portion and the central liner portion is made of asingle piece.

According to a possible embodiment, each one of the left liner portion,the right liner portion and the central liner portion is made via amolding process or an additive manufacturing process.

According to a possible embodiment, the liner assembly is made ofexpanded polystyrene (EPS).

According to a possible embodiment, the helmet further includes a chinbrace coupled to the left and right chin segments to reinforce the leftand right chin segments within the cavity.

According to a possible embodiment, the chin brace extends along theperiphery of the frontal opening.

According to a possible embodiment, the chin brace is coupled to theleft and right chin segments via at least one fastener.

According to another aspect, a helmet liner assembly for installationwithin a cavity of a helmet shell along an inner surface thereof isprovided. The liner assembly includes a lateral liner portion includinga left liner portion and a right liner portion, each of the left andright liner portions having an outer surface complementarily shapedrelative to left and right inner surface portions of the inner surface,respectively, and configured to engage with same, where the left linerportion includes a left chin segment, and the right liner portionincludes a right chin segment, the left and right chin segments beingconfigured to engage one another proximate a front section of the helmetshell; and a central liner portion engageable between the left and rightliner portions and having an outer surface complementarily shapedrelative to a central inner surface portion for engagement therewith.

According to another aspect, a method of installing a helmet linerassembly as defined above is provided. The method includes inserting theleft liner portion within the cavity for engagement with a left innersurface portion; inserting the right liner portion within the cavity forengagement with a right inner surface portion; and inserting the centralliner portion within the cavity between the left and right linerportions for engagement therewith.

According to a possible embodiment, the steps of inserting the leftliner portion and the right liner portion within the cavity are donegenerally simultaneously.

According to another aspect, a method for installing a helmet linerassembly within a helmet shell is provided. The method includesinserting a left liner portion made of a single piece of material withina cavity of the helmet shell for engagement with a left inner surfaceportion thereof; inserting a right liner portion made of a single pieceof material within the cavity for engagement with a right inner surfaceportion thereof; and inserting a central liner portion made of a singlepiece within the cavity between the left and right liner portions forengagement therewith, the central liner portion being configured to biasthe left and right liner portions against corresponding inner surfaceportions of the helmet shell when engaged between the left and rightliner portions.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a helmet having a helmet shell and aliner assembly, according to an embodiment.

FIG. 2 is a perspective view of the helmet shown in FIG. 1 , showing theliner assembly (left) separated from the helmet shell (right).

FIGS. 3 and 4 are right-side and left-side exploded perspective views ofthe liner assembly shown in FIG. 2 , showing a central liner portionprovided between left and right liner portions, according to anembodiment.

FIG. 5 is a perspective view of the central liner portion shown in FIGS.3 and 4 , according to an embodiment.

FIG. 6 is a front view of the helmet shown in FIG. 1 .

FIG. 7 is a left-side view of the helmet shown in FIG. 1 .

FIG. 8 is a cross-sectional view of the helmet shown in FIG. 6 , takenalong the line 8-8.

FIG. 9 is a cross-sectional view of the helmet shown in FIG. 7 , takenalong the line 9-9.

FIGS. 10 and 11 are respectively left-side and right-side perspectiveviews of the liner assembly according to an embodiment, showing a chinbrace coupled to the liner assembly.

FIG. 12 is a perspective view of another embodiment of a helmet, thehelmet being provided with a breathguard.

FIG. 13 is a top cross-sectional of another embodiment of the helmet,showing a ventilation conduit defined in a thickness of the helmetshell.

FIGS. 14 and 15 are cross-sectional views of a helmet provided with theliner assembly shown in FIG. 3 , showing a gap defined between thecentral liner portion and the helmet shell and visors positioned in alowered position (FIG. 14 ), and showing a secondary visor positioned ina raised position within the gap (FIG. 15 ).

FIG. 16 is a cross-sectional view of the helmet, showing forces appliedto various parts of the helmet when worn by a wearer, according to anembodiment.

FIGS. 17 to 23 are various perspective views of the helmet, illustratingan exemplary method for installing the liner assembly within the helmetshell, with the left and right liner portions being initially insertedwithin the helmet shell (FIGS. 17 and 18 ) and positioned againstcorresponding sides of the helmet shell (FIGS. 19 and 20 ), and with thecentral liner portion being subsequently inserted within the helmetshell between the left and right liner portions (FIGS. 21 to 23 ).

FIG. 24 is a perspective view of the liner assembly shown in FIGS. 10and 11 , showing a chin brace secured to the left and right linerportions via fasteners, according to an embodiment.

DETAILED DESCRIPTION

As will be explained below in relation to various embodiments, thepresent disclosure describes a helmet for use in various activities andsports, such as snowmobiling, for example. The helmet includes a helmetshell provided with a liner assembly installed within a cavity definedby the helmet shell. The liner assembly is complementarily shaped andengages the inner surface of the helmet shell (e.g., the surfacedefining the cavity) which at least partially reduces relative movementbetween the liner assembly and the helmet shell. In some embodiments,the liner assembly includes a plurality of portions engaging andinterlocked with one another to facilitate insertion of the linerassembly within the cavity. For example, one portion of the linerassembly can be inserted within the cavity at a time, which can then beinterlocked and assembled within the cavity. The liner assembly canfurther define a self-locking assembly whereby interlocking the portionsof the liner assembly to one another at least partially secures theportions together and within the cavity.

With reference to FIGS. 1 and 2 , a helmet 10 is shown in accordancewith a possible embodiment. In this embodiment, the helmet 10 includes aprotective helmet shell 12 having an inner surface 14 defining a cavity16 shaped and configured to receive a wearer's head, such as via abottom opening 20. The helmet shell 12 further defines a front opening18 communicating with the cavity 16 in order to allow the wearer to see.In this embodiment, the helmet 10 has a liner assembly 100 providedwithin the cavity 16 for engaging the inner surface 14 of the helmetshell 12. It is appreciated that the liner assembly 100 can define aprotective structure to be installed within the cavity 16 to improvecomfort and protection of the wearer. The liner assembly 100 can be asoft or padded lining made of Expanded Polystyrene (EPS) foam, forexample. However, it is appreciated that other configurations and/ormaterial can be used to provide a liner to the helmet 10.

In the illustrated embodiment, the helmet 10 is a full-face type helmet,where the chin guard 22 forms part of the helmet shell 12 (i.e., thechin guard is static). Having a static chin guard reduces the weight ofthe helmet 10 since the chin guard 22 does not require apivoting/rotating mechanism, such as a hinge, to pivotally connect thechin guard 22 to the helmet shell 12. By reducing the weight of thehelmet 10, the stress applied to the wearer's head and neck canaccordingly be reduced, thus increasing overall comfort when wearing thehelmet 10. However, it is appreciated that the liner assembly describedherein can be used with other types of helmets than full-face typehelmets.

As seen in FIGS. 2, 3 and 4 , the liner assembly 100 can include aplurality of liner portions adapted to be connected to one another. Inthis embodiment, the liner assembly 100 includes a lateral liner portion102, and a central liner portion 110 configured to engage one another toform an overall structure of the liner assembly 100. The lateral linerportion 102 can be adapted to engage lateral portions of the innersurface 14 of the helmet shell 12, and the central liner portion 110 canbe adapted to engage a central portion of the inner surface 14. Itshould be understood that, as used herein, the lateral portions canrefer to sections of the liner assembly adapted to cover at least thetemporal regions of the wearer's head, which can include the ears, thetemples, the cheeks, portions of the back of the head, portions of thejaw and/or portions of the chin, among others.

In some embodiments, the lateral liner portion 102 can include a leftliner portion 104 and a right liner portion 106 adapted to engagerespective lateral portions of the inner surface 14 of the helmet shell12. More specifically, the left liner portion 104 is adapted to engage aleft inner surface portion, and the right liner portion 106 is adaptedto engage a right inner surface portion. The central liner portion 110is illustratively provided between the left and right liner portion 104,106 and engages a central inner surface portion of the inner surface 14.The central liner portion 110 is further adapted to engage the lateralliner portion (e.g., the left and right liner portions 104, 106), aswill be described further below.

In this embodiment, the left and right liner portions 104, 106 eachinclude an outer surface complementarily shaped relative to thecorresponding inner surface portion. This configuration can at leastpartially reduce relative movement between the left and right linerportions and the helmet shell 12. More particularly, the left linerportion 104 can engage the left inner surface portion such that thecomplementarily-shaped features engage one another to prevent, or atleast reduce movement of the left liner portion relative to the leftinner surface portion. It is appreciated that the same is applicable forthe right liner portion 106 in relation with the right inner surfaceportion, and for the central liner portion 110 in relation with thecentral inner surface portion.

In some embodiments, the helmet shell 12 includes helmet mountingsections 30 used in relation with a visor assembly (shown in FIGS. 2 and9 ), where components used for pivotally connecting one or more visorsare coupled to the helmet on or around the helmet mounting sections 30.As seen in FIG. 9 , the helmet mounting sections 30 are depressed on thehelmet shell and at least partially extend within the cavity 16. Assuch, the complementarily-shaped portion of the left and/or right linerportions 104, 106 are configured to cooperate with the inwardlyextending part of the helmet mounting sections 30, which contributes toblocking relative movement between the liner portions and the helmetshell. It should be noted that the central liner portion 110 cansimilarly engage a corresponding profile which can be defined along thecentral inner surface portion, for example, to block relative movementtherebetween when engaged together.

In this embodiment, the shape and size of the lateral portions of theliner assembly 100 can assist in preventing disengagement of the linerassembly 100 from within the cavity 16. For example, the left and rightliner portions 104, 106 extend higher and lower within the cavity 16than the widest point of the helmet. This feature enables the left andright liner portions 104, 106 to “sit” along their respective innersurface portions and further reduces relative movement between the linerportions and the helmet shell. In addition, the helmet shell can includea bottom lip 40 defined about a periphery of the bottom opening 20, asillustrated in FIGS. 8 and 9 . The bottom lip can be adapted to preventdisengagement of the liner assembly 100 from within the cavity onceinstalled along the inner surface (or at least reduce the risksthereof). As seen in FIGS. 8 and 9 , the bottom lip 40 can extendinwardly toward the cavity 16 to enable respective bottom sections ofthe liner portions to sit thereon. As such, downward movement of theliner assembly 100 (e.g., toward the bottom opening 20) is at leastpartially prevented.

With reference to FIGS. 3 and 4 , the central portion can includecentral engagement surfaces 112 extending along a given length on eitherside thereof. The left and right liner portions 104, 106 includerespective lateral engagement surfaces 114, 116 configured to engagewith the central engagement surfaces 112. In other words, the lateralliner portions (e.g., the left and right liner portions 104, 106) areadapted to be removably coupled to the central liner portion 110 via anengagement of the engagement surfaces with one another. In thisembodiment, the central engagement surfaces 112 and the lateralengagement surfaces 114, 116 can include complementarily-shaped featuresconfigured to define an interlocking relationship between the linerportions, and thus enable interlocking the liner portions together.

The complementarily-shaped features can also be adapted to assist inpositioning the liner portions relative to one another and facilitatecoupling the liner portions together in the desired configuration. Forexample, the central liner portion 110 can be provided with one or moreprojections 115 extending from the central engagement surfaces 112, andthe left and right liner portions can be provided with correspondingrecesses 125 shaped and sized to receive the projections 115 therein.The projections 115 can be adapted to prevent, or at least reducerelative movement between the corresponding lateral liner portion andthe central liner portion 110 when engaged together.

As seen in FIGS. 1 and 3 to 5 , the central engagement surfaces 112 canextend along substantially the entire length of the central linerportion 110. In this embodiment, the central liner portion 110 isarcuate to conform to the inner surface 14 of the helmet shell 12, andincludes a rear end 110 a adapted to be positioned proximate the bottomopening 20 at a back section 15 of the helmet shell 12, and a front end110 b adapted to be positioned proximate an upper periphery 19 of thefront opening 18 (seen in FIG. 1 ). In some embodiments, the projections115 and recesses 125 can be spaced along the length of the central andlateral engagement surfaces 112, 114, 116 to define a plurality ofengagement joints on each side of the central liner portion 110. It isnoted that the engagement joints defined on a left side of the centralliner portion 110 can be aligned with the engagement joints defined on aright side thereof. In other words, the projections 115 are axiallyaligned with one another on opposite sides of the central liner portion110. However, it is appreciated that other configurations are possibleand may be used to assist in positioning the liner portions relative toone another and facilitate coupling the liner portions together in thedesired configuration.

In this embodiment, the projections 115 are generally cone-shaped andinclude a base tapering inwardly to an apex, with the recesses 125 beingcomplementarily shaped for receiving the cone-shaped projections. Itshould be understood that the projections 115 and recesses 125 can haveother shapes and configurations enabling engagement with one another,such as rectangular, semi-circular, triangular, frustoconical, etc., forexample. It should thus be noted that the liner portions can be securedwithin the cavity of the helmet shell 12 without the use of adhesives orfasteners. The liner portions are held in place relative to one anothervia the interlocking and complementarily-shaped features (e.g.,projections 115 and recesses 125) to form the liner assembly 100, andthe liner assembly 100 is held in place within the cavity 16 via thecomplementarily-shaped outer surface of the liner assembly 100 and innersurface 14 of the helmet shell 12.

With reference to FIG. 9 , in addition to FIGS. 3 to 5 , the centralliner portion 110 can include a rabbeted edge 120 defined and extendingalong the left and right sides thereof (e.g., similar to the centralengagement surfaces 112). The rabbeted edges 120 can include a pair ofsurfaces angled relative to one another by any suitable angle. Forinstance, the rabbeted edges 120 can include a first surface 121, whichcan be generally vertical, and a second surface 123, which can begenerally horizontal, connected to one another to form the rabbet. Insome embodiments, the first surface 121 can be parallel to the centralengagement surfaces 112, although other configurations are possible. Aswill be described further below, the second surface 123 can be angledrelative to the first surface 121 such that the angle definedtherebetween differs from a right angle. For instance, the secondsurface 123 can extend downwardly (e.g., the angle is greater than 90degrees) which can enable the central liner portion 110 to wedge andbias the lateral liner portions outwardly.

In this embodiment, the left and right liner portions 104, 106respectively include an overhang 124, 126 adapted to extend inwardly(e.g., toward one another) within the cavity 16. The overhangs 124, 126can be configured to contact and engage the rabbeted edges 120 onrespective sides to define rabbet joints 128 along the length of thecentral liner portion 110. In some embodiments, the formed rabbet joints128 can extend along the entire length of the central liner portion 110(e.g., from the rear end 110 a to the front end 110 b) and are generallysymmetrical on either side of the central liner portion 110. It shouldbe understood that the rabbeted edges 120 of the central liner portion110 and the overhangs 124, 126 of the left and right liner portions canbe part of the complementarily-shaped features previously described,along with the projections 115 and recesses 125, for example. In someembodiments, the rabbeted edges 120, the overhangs 124, 126 and thelateral engagement surfaces 114, 116 can cooperate to define a steppedjoint (e.g., in the shape of a staircase) between the central linerportion 110 and each of the left and right liner portions 104, 106.

Still referring to FIGS. 3, 4 and 9 , the surfaces 121, 123 of therabbeted edge 120 can be angled relative to each other in a manner suchthat the central liner portion 110 is configured to bias the lateralliner portions 104, 106 toward the helmet shell (e.g., away from thecentral liner portion 110). In this embodiment, the angled surfaces ofthe rabbeted edge 120 can define a wedge 130 configured to bias the leftliner portion 104 and the right liner portion 106 towards the left andright inner surface portions, respectively. As such, it is noted thatthe engagement of the central liner portion 110 between the lateralliner portions 104, 106 forms the liner assembly 100 and simultaneouslyassists in securing the liner assembly 100 within the cavity 16. In thisembodiment, the outwardly oriented biasing force generated by the wedge130 of the central liner portion 110 is sufficient to maintain thelateral liner portions 104, 106 in engagement with respective sides ofthe helmet shell without disengaging the projections 115 from therecesses 125 (i.e., without disengaging the lateral engagement surfaces114, 116). In some embodiments, the central engagement surface 112 isangled and adapted to generate an outwardly biasing force, similar tothe one generated by the surface(s) of the rabbeted edges 120.

Referring FIGS. 3 to 7 , the left and right liner portions 104, 106include left and right chin segments 105, 107, respectively. In thisembodiment, the chin segments 105, 107 extend along the chin guard 22 onrespective sides thereof and engage one another proximate a frontsection 13 of the helmet shell 12. The chin segments 105, 107 areadapted to engage one another such that they extend along a lowerperiphery 21 of the front opening 18. In some embodiments, the chinsegments 105, 107 engage one another substantially at a middle point ofthe chin guard 22, although other configurations are possible. It isthus noted that the left and right liner portions 104, 106 can begenerally symmetrical relative to a central plane, which corresponds tothe location where the chin segments 105, 107 engage one another.

The left and right chin segments 105, 107 can include engagementsurfaces 144, 146 configured to contact and engage one another whenassembling the liner assembly 100 within the helmet shell 12. Theengagement surfaces 144, 146 can be relatively flat or planar and, insome embodiment, are configured to engage one another in the centralplane, although other configurations are possible, such as having angledengagement surfaces, for example. In a similar fashion as the previouslydescribed central and lateral engagement surfaces 112, 114, 116, theengagement surfaces of the chin segments 105, 107 can be provided withcomplementarily-shaped features configured to assist in positioning thechin segments 105, 107 relative to one another and facilitate couplingthe chin segments together in the desired configuration.

As seen in FIGS. 3 and 4 , the engagement surface of one of the chinsegments 105, 107 can include a protrusion 145, and the engagementsurface of the other one of the chin segments 105, 107 can include arecess 155, or notch, configured to receive the protrusion 145 therein.As such, it is noted that inserting the protrusion 145 within the recess155 assists in positioning the chin segments 105, 107 relative to eachother. In this embodiment, the chin segments include a single protrusion145, and a single recess 155, although other configurations and/orcomplementarily-shaped features are possible and may be used. Forexample, complementarily shaped hooks and edges can be defined andconfigured to secure the chin segments to one another (e.g., without theuse of adhesive or additional fasteners).

Now referring to FIGS. 10 and 11 , the helmet 10 can be provided with achin brace 24 coupled to the liner assembly 100 and configured toreinforce a portion thereof. More specifically, the chin brace 24 isadapted to be connected to the lateral liner portions and extend alongat least a portion of the chin segments 105, 107 for reinforcingpurposes. In this embodiment, the chin brace 24 covers the chin segmentswithin the cavity, and includes a top edge extending along the peripheryof the front opening 18, as seen in FIG. 1 . In some embodiments, thechin brace 24 can be adapted to reinforce other sections of the lateralliner portions (e.g., the left and right liner portions) in addition tothe chin segments 105, 107. As seen in FIGS. 10 and 11 , the chin brace24 can be coupled to the left and/or right liner portions via one ormore fasteners 160, although other means of connecting the chin brace 24can be used. The fastener 160 can be configured to extend through thechin brace, the chin segment and the chin guard 22, thereby securingthese components together (i.e., thereby further securing thecorresponding liner portion relative to the helmet shell).

It should be noted that integrating the chin segments of the linerassembly 100 with the lateral liner portions (e.g., with the left andright liner portions) increases control of the overall size of the linerassembly and improves cooperation with the internal features of thehelmet shell (e.g., inner surface, etc.). Other components can benefitfrom the absence of joints or connectors between the chin segment(s) andthe lateral liner portions, and the inclusion of the chin brace forincreased rigidity and support. For example, and with reference to FIG.12 , in some embodiments, the helmet 10 can include a visor assembly200, which can include a breathguard, or breathbox 204 coupled to aninner side of the visor 202, such as along a lower edge thereof. Thebreathguard can thus be adapted to cooperate with the lower periphery ofthe front opening 18 of the helmet shell and/or with the chin segments.As such, having better defined, configured and/or sized chin segments(e.g., due to their integration with the lateral liner portions) canimprove cooperation and facilitate coupling between the components ofthe visor assembly 200 and the liner assembly 100, for example. Anexemplary visor assembly including a breathguard is described in U.S.Pat. No. 11,297,891, the content of which is incorporated by referenceherein in its entirety. A breath deflector can alternatively, oradditionally be provided within the cavity, allowing for redirecting thewearer's breath (e.g., away from the inner surface of the visor).

In some embodiments, having better defined, configured and/or sized chinsegments can facilitate positioning other components, such asventilation conduits defined through the liner and/or helmet shell. Forexample, and with reference to FIG. 13 , a conduit 216 can be definedwithin a thickness of the helmet shell 12 of the liner or a combinationthereof. The conduit can have an inlet 212 communicating with the cavityto draw in breath from the wearer, for example, and one or more outlets214, 214B, 214C defined at the rear of the helmet and communicating withthe environment to expel the airflow from within the cavity to outside.Therefore, it is noted that having integrated chin segments canfacilitate the addition of airflow conduits, among other possibilities.An exemplary ventilation system including airflow conduits is describedin U.S. Pat. No. 11,202,482, the content of which is incorporated byreference herein in its entirety.

With reference to FIGS. 2 to 5, 8 , along with FIGS. 14 to 16 , thehelmet 10 can include the visor assembly 200 which can include a pair ofvisors, such as a main visor 202, and a secondary visor 206 positionedgenerally behind the main visor 202. In some embodiments, the secondaryvisor 206 corresponds to a sun visor, which can be used when required(e.g., by covering a portion of the front opening 18, as seen in FIG. 14), and otherwise stored within the helmet shell away from the frontopening 18, as seen in FIG. 15 . In this embodiment, the central linerportion 110 includes a frontal segment 140 shaped and adapted to bespaced from the inner surface 14 of the helmet shell 12, therebydefining a gap 142 therebetween. The gap 142 can be adapted to receiveand house the sun visor 206 when desired (e.g., when the sun visor 206is not required). In other words, the sun visor 206 can be selectivelyrotated upwardly and moved within the gap 142 defined between the linerassembly 100 and the helmet shell 12.

As seen in FIGS. 2 to 5 , the lateral liner portions 104, 106 can besimilarly provided with forward segments 147, 149 adapted to be spacedfrom the inner surface of the helmet shell 12, such that the gap isfurther defined between the inner surface of the helmet shell 12 and theforward segments 147, 149. It should thus be noted that the forwardsegments 147, 149 and the frontal segment 140 can cooperate to form acontinuous surface when the liner assembly 100 is assembled. As such, itis noted that the frontal segment 140 of the central liner portion 110engages and cooperates with the forward segments provided laterallythereto, which can be adapted to reinforce and provide support on eitherside of the frontal segment 140.

As seen in FIG. 16 , when wearing the helmet, the head of thewearer/user can apply a force or pressure on the front section of theliner assembly 100, such as on the frontal segment 140 of the centralliner portion. If unsupported, the frontal segment 140 can, under theeffect of the applied pressure, bend outwardly within the gap 142 (e.g.,the frontal segment can flex about point A). This can cause damage toand/or malfunction of the sun visor 206 or related mechanisms positionedwithin the gap 142. However, by supporting the frontal segment 140 withthe corresponding segments of the lateral liner portions, the movementof the frontal segment caused by pressure applied from within the helmetis negated, or at least partially reduced. This can increase thelifespan of the liner assembly 100 by reducing undesired movement of oneor more portions thereof, and similarly increase lifespan of the sunvisor 206 since damage can be avoided or at least reduced. It is alsonoted that, by reducing or preventing the bending motion of the frontalsegment 140 due to internal pressures, the gap 142 can remain relativelynarrow, thereby reducing the overall required size of the helmet.

Referring to FIGS. 17 to 23 , the liner assembly 100 can be assembledfollowing various methods. For instance, in one embodiment, the left andright liner portions 104, 106 can be inserted together within the cavity16 through the bottom opening 20 (FIG. 17 ). As illustrated, in order tofacilitate insertion, the rear section of the left and right linerportions 104, 106 can be inserted first, followed by a rotation of theleft and right liner portions 104, 106 in the desired orientation (FIG.18 ). In this embodiment, the desired orientation includes an alignmentbetween the chin guard 22 and the chin segments 105, 107, among others.Once the lateral liner portions are in the desired orientation, the leftand right liner 104, 106 portions can be separated within the cavity 16(e.g., following arrows S1 and S2 seen in FIG. 19 ) to engage respectivelateral inner surface portions of the helmet shell 12 (FIG. 20 ). Theleft and right liner portions 104, 106 are complementarily shapedrelative to the lateral inner surface portions and can thus at leastpartially self-lock into position by engaging one or morecomplementarily-shaped features. It is noted that separating the leftand right liner portions includes separating temporal regions thereof,while the chin segments engage one another along the chin guard. It isappreciated that the chin segments can alternatively be made to engageone another during insertion of the liner portions within the cavity orat least be drawn closer to each other to minimize their overall volumeand facilitate their insertion within the cavity (seen in FIG. 17 ).

With the lateral liner portions 104, 106 in position within the cavity16, the central liner portion 110 can be inserted through the bottomopening 20 to engage between the previously installed left and rightliner portions (FIG. 21 ). In some embodiments, the central linerportion 110 is wedged between the lateral liner portions to assemble theliner assembly 100 and secure the assembled liner assembly 100 withinthe cavity 16 (e.g., following arrow S3 seen in FIG. 21 ). In thisembodiment, the central liner portion 110 is inserted between thelateral liner portions in order to have the outer surface thereof engagethe inner surface of the helmet shell 12, and to further have theprojections 115 engage the recesses (e.g., following arrows S4 and S5 inFIG. 22 ) for coupling the central and lateral liner portions together(FIGS. 22 and 23 ). The chin brace can then be coupled to the linerassembly 100 to reinforce the corresponding portions thereof. However,as seen in FIG. 24 , the chin brace 24 can be connected and/or securedto the lateral liner portions, 106 prior to inserting the central linerportion 110. As such, the lateral liner portions 104, 106 are furthersecured in position within the cavity and relative to one another, whichcan facilitate the insertion and positioning of the central linerportion 110.

In this embodiment, the liner assembly 100 is formed of threesingle-piece units, which are designed and configured to take up as muchspace as possible along the inner surface of the cavity. Having biggerpieces of the liner assembly 100 can facilitate assembly (e.g., fewerpieces to assemble), and improve connection of the liner assembly 100 tothe helmet shell 12. In other words, inserting the central liner portion110 between the left and right liner portions 104, 106 can tighten theliner assembly 100 within the cavity 16, thereby acting as aself-locking mechanism to secure the liner assembly 100 relative to thehelmet shell 12. As mentioned, each liner portion can be made of asingle piece of material, such as expanded polystyrene (EPS), forexample, and can be manufactured using any suitable method, such as viaa molding process. It should be noted that other materials can be used,and that other manufacturing methods can be employed to create the linerpieces, such as via an additive manufacturing process (e.g., 3Dprinting).

It should be appreciated from the present disclosure that the variousembodiments of the helmet, liner assembly and related components enablefor a more robust helmet, with a simplified method of assembling andinstalling the liner assembly within the helmet shell. The linerassembly is shaped and configured to complement the inner surface of thehelmet shell. As such, gaps and misalignments are minimized orcompletely prevented, which can provide additional comfort andprotection to the wearer of the helmet. By complementing the innersurface of the helmet shell, the liner assembly is also constrained andheld in position, i.e., there is practically no relative movementbetween the helmet shell and the different portions of the linerassembly. It is noted that the liner assembly is constrained and securedwithout the use of an adhesive or additional/external fasteners.

The central liner portion advantageously engages between the left andright liner portions in an interlocking manner to form a robust linerassembly which holds together well, while also biasing the left andright liner portions away from the central liner portion and inengagement with respective inner surface portions. As such, the centralliner portion acts as a wedge between the lateral liner portions, butalso defines a self-locking mechanism of the liner assembly for securingit within the helmet shell, and without the use of adhesives. Further,when wearing the helmet, the central liner portion extends from theoccipital region to the frontal region of the wearer, thereby providingincreased protection. The central liner portion is also supported oneither side thereof by the rabbet joints defined between the central andlateral liner portions, and by the projections and recesses. In otherwords, the central liner portion does not include a cantileveredportion, which can bend, or otherwise flex, and cause malfunctions anddamages to other components of the helmet.

Finally, by integrating the chin segments to the temporal region of thelateral liner portions, the helmet has a reinforced chin portion of thehelmet, which provides improved protection proximate the front section(e.g., around the chin and jaw of the wearer). The integrated chinsegments also benefit other components and systems of the helmet, suchas improved cooperation with visor assemblies including a breathguard,or ventilation systems having conduits defined in the liner and/orthrough the helmet shell, for example.

The present disclosure may be embodied in other specific forms withoutdeparting from the subject matter of the claims. The described exampleembodiments are to be considered in all respects as being onlyillustrative and not restrictive. For example, in the embodimentsdescribed herein, the lateral liner portions includedisconnected/independent left and right liner portions. However, inalternate embodiments, the lateral liner portion can be formed as asingle unit, where the left liner portion is connected to the rightliner portion, such as via a connecting liner portion adapted to extendbetween the left and right liner portions (e.g., around a neck and/orthe back of the head of the wearer).

The present disclosure intends to cover and embrace all suitable changesin technology. The scope of the present disclosure is, therefore,described by the appended claims rather than by the foregoingdescription. The scope of the claims should not be limited by theembodiments set forth in the examples, but should be given the broadestinterpretation consistent with the description as a whole.

As used herein, the terms “coupled”, “coupling”, “attached”, “connected”or variants thereof as used herein can have several different meaningsdepending in the context in which these terms are used. For example, theterms coupled, coupling, connected or attached can have a mechanicalconnotation. For example, as used herein, the terms coupled, coupling orattached can indicate that two elements or devices are directlyconnected to one another or connected to one another through one or moreintermediate elements or devices via a mechanical element depending onthe particular context.

In the present disclosure, an embodiment is an example or implementationof the described features. The various appearances of “one embodiment,”“an embodiment” or “some embodiments” do not necessarily all refer tothe same embodiments. Although various features may be described in thecontext of a single embodiment, the features may also be providedseparately or in any suitable combination. Conversely, although thehelmet and/or the liner assembly may be described herein in the contextof separate embodiments for clarity, it may also be embodied in a singleembodiment. Reference in the specification to “some embodiments”, “anembodiment”, “one embodiment”, or “other embodiments”, means that aparticular feature, structure, or characteristic described in connectionwith the embodiments is included in at least some embodiments, but notnecessarily in all embodiments.

In the above description, the same numerical references refer to similarelements. Furthermore, for the sake of simplicity and clarity, namely soas to not unduly burden the figures with several references numbers, notall figures contain references to all the components and features, andreferences to some components and features may be found in only onefigure, and components and features of the present disclosure which areillustrated in other figures can be easily inferred therefrom. Theembodiments, geometrical configurations, materials mentioned and/ordimensions shown in the figures are optional, and are given forexemplification purposes only.

In addition, although the optional configurations as illustrated in theaccompanying drawings include various components and although theoptional configurations of the helmet as shown may consist of certaingeometrical configurations as explained and illustrated herein, not allof these components and geometries are essential and thus should not betaken in their restrictive sense, i.e., should not be taken as to limitthe scope of the present disclosure. It is to be understood that othersuitable components and cooperation thereinbetween, as well as othersuitable geometrical configurations may be used for the embodiment anduse of the helmet, and corresponding parts, as briefly explained and ascan be easily inferred herefrom, without departing from the scope of thedisclosure.

1. A helmet comprising: a helmet shell having an inner surface defininga cavity and a frontal opening; a liner assembly for engagement with thehelmet shell within the cavity, the liner assembly comprising: a lateralliner portion comprising a left liner portion and a right liner portion,each of the left and right liner portions having an outer surfacecomplementarily shaped relative to left and right inner surface portionsof the inner surface, respectively, and configured to engage with same,where the left liner portion includes a left chin segment, and the rightliner portion includes a right chin segment, the left and right chinsegments being configured to engage one another proximate a frontsection of the helmet shell; and a central liner portion engageablebetween the left and right liner portions and having an outer surfacecomplementarily shaped relative to a central inner surface portion forengagement therewith.
 2. The helmet of claim 1, wherein thecomplementarily shaped outer surfaces of the left and right linerportions and the left and right inner surface portions are adapted toengage one another to at least partially reduce relative movementbetween the left and right liner portions and the helmet shell.
 3. Thehelmet of claim 1, wherein the central liner portion comprises centralengagement surfaces provided on either side thereof, and wherein theleft and right liner portions include respective lateral engagementsurfaces configured to engage with the central engagement surfaces. 4.The helmet of claim 3, wherein each central engagement surface comprisesone or more projections extending therefrom, and wherein each lateralengagement surface comprises one or more recesses adapted to receiverespective projections therein, the projections and recesses beingadapted to cooperate to at least partially reduce relative movementbetween the central liner portion and the left and right liner portions.5. The helmet of claim 3, wherein the central engagement surfaces areshaped and sized to bias the left and right liner portions outwardly andaway from the central liner portion upon engagement of the central linerportion between the left and right liner portions.
 6. The helmet ofclaim 1, wherein the central liner portion comprises rabbeted edgesextending along left and right sides thereof.
 7. The helmet of claim 6,wherein each rabbeted edge comprises at least one angled surfaceconfigured to bias the left and right liner portions outwardly and awayfrom the central liner portion upon engagement of the central linerportion between the left and right liner portions.
 8. The helmet ofclaim 6, wherein the left and right liner portions each include anoverhang adapted to engage respective rabbeted edges and define rabbetjoints therewith.
 9. The helmet of claim 1, further comprising a bottomopening, and wherein the central liner portion extends from a rearsection of the helmet shell proximate the bottom opening, along thecentral inner surface portion and to the front section proximate thefrontal opening.
 10. The helmet of claim 1, wherein the central linerportion comprises a frontal segment adapted to be spaced from the innersurface of the helmet shell, thereby defining a gap therebetween. 11.The helmet of claim 10, wherein the left and right liner portionscomprise respective forward segments adapted to be spaced from the innersurface of the helmet shell, and wherein the gap is further definedbetween the inner surface of the helmet shell and the forward segments.12. The helmet of claim 1, further comprising a chin guard provided atthe front section of the helmet shell and at least partially defining aperiphery of the frontal opening, and wherein the left and right chinsegments extend along the chin guard on respective sides thereof andengage one another substantially at a middle point of the chin guard.13. The helmet of claim 1, wherein each one of the left and right chinsegments includes an engagement surface adapted to engage the engagementsurface of the other one of the left and right chin segments.
 14. Thehelmet of claim 13, wherein one of the engagement surfaces comprises aprotrusion, and wherein another one of the engagement surfaces comprisesa recess adapted to receive the protrusion therein when the engagementsurfaces engage one another.
 15. The helmet of claim 1, wherein each oneof the left liner portion, the right liner portion and the central linerportion is made of a single piece.
 16. The helmet of claim 1, furthercomprising a chin brace coupled to the left and right chin segments andextending along the periphery of the frontal opening to reinforce theleft and right chin segments within the cavity.
 17. A helmet linerassembly for installation within a cavity of a helmet shell along aninner surface thereof, the helmet liner assembly comprising: a lateralliner portion comprising a left liner portion and a right liner portion,each of the left and right liner portions having an outer surfacecomplementarily shaped relative to left and right inner surface portionsof the inner surface, respectively, and configured to engage with same,where the left liner portion includes a left chin segment, and the rightliner portion includes a right chin segment, the left and right chinsegments being configured to engage one another proximate a frontsection of the helmet shell; and a central liner portion engageablebetween the left and right liner portions and having an outer surfacecomplementarily shaped relative to a central inner surface portion forengagement therewith.
 18. A method of installing a helmet liner assemblyas defined in claim 17 within a helmet shell, comprising: inserting theleft liner portion within the cavity for engagement with the left innersurface portion; inserting the right liner portion within the cavity forengagement with the right inner surface portion; and inserting thecentral liner portion within the cavity between the left and right linerportions for engagement therewith.
 19. The method of claim 18, whereinthe steps of inserting the left liner portion and the right linerportion within the cavity are done generally simultaneously.
 20. Amethod of installing a helmet liner assembly within a helmet shell,comprising: inserting a left liner portion made of a single piece ofmaterial within a cavity of the helmet shell for engagement with a leftinner surface portion thereof; inserting a right liner portion made of asingle piece of material within the cavity for engagement with a rightinner surface portion thereof; and inserting a central liner portionmade of a single piece within the cavity between the left and rightliner portions for engagement therewith, the central liner portion beingconfigured to bias the left and right liner portions againstcorresponding inner surface portions of the helmet shell when engagedbetween the left and right liner portions.